REMOVAL & INSTALLATION
See Figures 1, 2 and 3
The fuel pump is part of the fuel sender assembly located inside the fuel tank.
- Release the fuel system pressure and disconnect the negative battery cable.
- Drain the fuel tank, then raise and safely support the vehicle.
- Remove the fuel tank from the vehicle.
- Clean the area surrounding the sender assembly to prevent contamination of the fuel system.
- Using tool J-24187 or equivalent, remove the sending unit retaining cam. Remove the fuel sender and O-rings from the tank. Discard the O-rings.
- If necessary, separate the fuel pump from the sending unit assembly.
- If removed, install the fuel pump to the sending unit. If the strainer was removed, it must be replaced with a new one.
- Inspect and clean the O-ring mating surfaces.
- Install a new O-ring in the groove around the tank opening. If applicable, install a new O-ring on the fuel sender feed tube.
Install the fuel sender assembly as follows:
- The fuel pump strainer must be in a horizontal position, and when installed, must not block the travel of the float arm. Gently fold the strainer over itself and slowly position the sending assembly in the tank so the strainer is not damaged or trapped by the sump walls.
- Install the retaining cam using tool J-24187 or equivalent.
- Install the fuel tank assembly.
- Lower the vehicle.
- Fill the fuel tank, tighten the fuel filler cap and connect the negative battery cable.
- Turn the ignition switch to the ON position for 2 seconds, OFF for 10 seconds, then back to the ON position. Check for fuel leaks.
See Figure 4
- Relieve the fuel system pressure and check that there is an adequate quantity of fuel in the tank.
- Connect a fuel pressure gauge to the pressure connector fitting located on the end of the fuel rail.
- Make sure the ignition switch has been in the OFF position for at least 10 seconds and that all accessories are OFF.
- Turn the ignition switch ON and the pump will run for about 2 seconds. Note the system pressure with the pump running, it should be between 40-47 psi.
The ignition switch may have to be cycled to the ON position more than once to obtain maximum pressure. It is also normal for the pressure to drop slightly when the pump first stops, but it should then hold steady.
- If the pressure is not as specified, verify that fuel pump operation is heard in the tank.
- If fuel pump operation is not heard, inspect the fuel pump relay and wiring.
- If fuel pump operation is heard, inspect the filter and lines for restriction.
- Start the engine and make sure the pressure decreases about 3-10 psi at idle.
- If fuel pressure does not decrease, inspect the fuel pressure regulator and hose.
- Disconnect the fuel pressure gauge.